Hammer and method of fabricating same



Oct. 26, 1954 M, M -rm 2,692,626

HAMMER AND METHOD OF FABRICATING SAME Filed April 6, 1951 m H 111-" .1 A? 1/ 57 x; 20 z; 23 2/ IM! M M) 9L ---j a; 15 .a2 22 25 24 l-+ 5 2; a o

23 1x z 2; z;

, l M 20 r z;

MARVIN M. MART/N,

INVEN TOR.

A T TORNEK Patented Oct. 26, 1954 ATENT OFFICE Marvin M. Martin, South Gate, Calif., assignor to Martool, Inc., South Gate, Calif., a corporation of California Application April 6, 1951, Serial No. 219,603

8 Claims. Cl. 145-36) This invention relates to hammers with special reference to hammers having relatively soft heads of lead, plastic materials and the like, and is directed to the problem of mounting such a molded head on a handle in such manner that the head and handle are effectively united for a long service life.

In the normal usage of such a hammer, the impacts of the head against work material and the centrifugal force engendered by swinging the hammer create excessive strains that tend to weaken the hammer structure to the point of separating the head from the handle. Various suggestions have been advanced heretofore for providing a permanent safe joint between the head and handle of such a hammer, but usually such constructions either are inadequate for meeting the strains of actual service or from the manufacturing view point are impractical.

The present invention achieves the required structural strength by providing what may be called a hammer frame in which a head sleeve and. a handle are structurally inter-locked by positive mutual engagement and in which a head or head body is cast in such manner as to additionally interlock the sleeve and handle.

Economy is achieved by using standard hollow stock material such as metal pipe or tubing for both the head sleeve and the handle and further economy is afforded by employing a rapid method of manufacture requiring relatively few and relatively simple fabrication steps.

To carry out this concept, a head sleeve cut from relatively large diameter tubular stock is bored from one side to receive the end portion of a handle cut from tubular stock of smaller diameter and a suitable procedure is carried out to unite the head sleeve and handle, thus to complete the hammer frame. In the preferred practice of the invention the handle is attached to the head sleeve in a positive manner both by welding and by mechanical interlocking engagement. The mutual interlocking engagement is accomplished simply by expanding the end portion of the handle after the end portion is inserted into the head sleeve.

The head or head body of lead, plastic, or other suitable material is then molded or cast to occupy the head sleeve, and imbedded engage:- ment of the handle with the sleeve-embraced molded head further interlocks the head and handle. Thus, a structurally efficient hammer is produced in a simple inexpensive manner from stock materials and the rugged hammer frame may be used indefinitely by discarding worn heads and molding new heads into the hammer frame as often as necessary.

It has been found that heads of widely different shapes are demanded in industry not only because the hammers are used for various purposes, but also because opinions differ as to the best shape of hammer head for a given purpose. Ordinarily it would be necessary to manufacture and stock many different models of the hammer to meet the deversified demand. A feature of the invention, however, is that the final step of casting or molding the head is a relatively simple procedure that may be carried out by the industrial purchaser. In practice, therefore, it is necessary to stock only the hammer frame comprising the interlocked head sleeve and handle, which hammer frame is sold as an article of manufacture for completion by the purchaser.

The various features and advantages of the invention may be understood from the accompanying drawings taken with the following detailed description.

In the drawings, which are to be regarded as merely illustrative,

Figure l is a side elevation of the presently preferred embodiment of the invention with portions shown in section;

Figure 2 is a top or plan view of the hammer frame;

Figure 3 is a section through the hammer head taken as indicated by the line 3-3 of Figure 1;

Figure 4 is a perspective view of an end portion of the handle prepared for insertion into the head sleeve; and

Figure 5 is a similar view of the end portion as expanded after insertion.

The principal parts of the preferred form of the invention shown in the drawings are a molded or cast head in the form of a body it carried by a hammer frame, generally designated H, which hammer frame comprises a cylindrical head sleeve 12 and a handle I3. An end portion of the handle l3 extends into the interior of the head sleeve I 2 and this end portion inside the head sleeve is suitably deformed or expanded for mechanical or structural interlock with the head sleeve. The handle I3 is not only interlocked directly with the head sleeve in this manner, but is also interlocked indirectly with the head sleeve by means of the head 10, since the handle is embedded in the head and the head in turn is embraced by the sleeve I2.

The structural relationships involved may be appreciated from a description of thepreferred fabrication procedure. First, the head sleeve I2 is cut to length from suitable tubular stock and then is bored to provide a peripheral opening It to receive the end portion of the handle [3. In the preferred practice of the invention it is contemplated that the inserted end of the handle l3 will be welded to the wall of the head sleeve [2 opposite from the "peripheral opening :HS, and such welding may be. facilitated bylboring a second peripheral opening I1 in the head sleeve 12 diametrically opposite from the first mentioned peripheral opening [6.

The smaller diameter tubing forthehandle 13 is cut to length and preferably is partially fiattened along a portion of its length toprovide .:a

narrowed grip portion 20. .=It 'is :also :desirable t to add an end fitting in the form of a metal plug 2i. This end fitting 2| .-.is formed .with a shank 22 dimensioned to fit intothe end of the handle 43 and is formed with a shoulder '23 :to abut the handle end. The metal fitting 2| is also formed with a radial endfiangez-M so that-when the end fitting is united with the :handle .13 .by welding 25 the radial end flange 2 4 forms an-enlargement on theouter end of .thehandle l3 that acts as a safeguard :torkeep the hammer from slipping from a workmans hand. If such a metal fitting 2| is.added, itisdesirableto bore a small hole .26 in ethehandle =I-3 to serveas a vent in the subsequent molding orrcasting of :the head body 10.

In preparationfor inserting the handle l;3.-into the head sleeve l2, at leastonea-slit-orslot, preferably longitudinal, :is cut in the end :portion. Thus, as shownin Figure-4, :two slots 2-! -positioned diametrically apart .are 20111, in the end portion of the handle-.l:3. ThErSlOtS 21 may, for example, be cut inch wide =and,.if:desired,'a inch 'hole -2-8 may-be bored-in the :opposite walls of the handle at the location of the two slots 21 prior-to the-actual cutting of .theslots.

The end portionof the :handle :l,3 yis then-inserted into the interior of the :head sleeve -.I2 through the peripheral :opening 16 and, ;if :the second peripheral opening I! is provided, :the leading end .of :the handle is extended tthrough the second opening ZITT or atzleast :brought flush with the outer rim of the second-:openingsoithat the end of'the:handleimayfbe weldedito thezhead sleeve with the welding operation performed from the exterior of'theheadsleeve. After this-welding operation the protruding portion of the handle 13 at the weld as well -as anyprotrudin welding maybe ground away to conform smoothly with the cylindrical configuration of the head sleeve. in Figure 1.

The next step is to expand or open up the two slots 21 of the handle 43 to 'deform theportion of the handle disposed within the 1 head sleeve 12. This operation may be conveniently and effectively performed simply-by driving a suitable swaging tool into the slots 21. -Any suitable swaging tool may be'used for-this purposeybut one having a suitablydimensioned guide'pinis preferred for the bore Z23 formed at the medial portion of each of the slots 2''! coacts with such a pin to locateand guide .thetool into he desired engagement withthe defining edges of [the slots. In this expandingoperation.theswaging tool may be driven throug'hbothslots;21'in.one operation to deform the handle asshown. infigure 5. This swaging action, in'locallyexpanding the handle, tends to shorten the handle andconsequently causes the same to .creep.further-.into

The finished welding is indicated 'at 30 4 the head sleeve [2 and the handle is free to creep in the opening 16 to the needed degree.

It will be seen, referring now to Figure 3, that the cross-sectional dimensions of the portion of the handle after the swaging action have been increased, so that the end portion of the handle is larger than 'the opening is through which it has beeniinserted. Thus, while the welding 30 directly connects the handle I3 to the head sleeve 12, sole reliance is not placed on the welding inasmuch .as .the expanded end portion of the handle [3 is too large for retraction through the opening [6 in the head sleeve l2. Thus, even :though'the welding .should fail the head sleeve can'not becomeseparated from the handle.

The tool "in this stage of completion can be soldasanaarticleof commerce for the final operation in the fabrication procedure of the ham mer may be carried out by the purchaser. This article, which consists of the head sleeve l2 with the :handle Ianow securely rfixed "tothe same, is shown in 2Figure22.

To completeathe'hammerythe purchaser merely molds 'or casts the head body It in such a man ner thatthe head body .occupies the interior of the rheadsleeve 1 2 andextends beyond the two end openings of the head sleeve. This operation requires merelylaiconventional mold having acavity of'the'desiredssizeand shape and it is not believed necessary to describe this molding operation, for it will be readily apparent to one skilled'in the art.

Whether-the molding operation is carried out by the'fabricator of the head sleeve and handle or :by the purchaser, the described construction 'for the hammerframe l l permits the material of the head'body l0, duringthe-molding operation, toextend or fiow into the interior of the handle 13 through the slots 21 andthe body material may be permitted to extend into the shank of the handle to any extent desired.

A feature of the'invention is the numerous-respects'in which the head-0r head body It! is engagedhy'the hammer frame ll. There-is interengagement between'the headand the hammer frame in that thematerial of the head extends into the shank of the handle, as indicated at 32in Figurel, and againin-the fact that the material of the hammerheadengages the rim of the=peripheralopening l1 ofthe head sleeve as indicated at 33. There isfurther inter-en agement by virtue of the fact that the head 10 may becast slightly oversize with respect to the innerdiameter of'the'headsleeve l2 so that the hea'disformed with anannular shoulder 35 abutting against each end of the .head sleeve [2, as shown in-Figure 1.

As best shown in Figure 3, there is further inter-engagement between'the head and the hammer frame in theway the-expanded end portion of the handlel3 is imbedded in the material ofthe head. Thus, it will be noted in Figure 3 that themaximum cross-dimension of the material of the head inside the diameter of the handle [3 is greater than the entrancesinto the interior ,of the handle through.the expanded slots 2'! so that thematerial 0f thehead is, in efiect, trapped by .the wallsof .the handle .13. It may also .bernotedin Figure-3 thatthe angular relation of thesplitwallsof the handle l3, relative to the surrounding circumferential wall ofthe sleeve 12, .entraps or.mobilizes the material .of the head 1.0 insidethe sleeve.

-A feature .of the .invention :is that the sleeve l2, which surrounds the head it}, is prevented from separating from the handle I3, first, by the previously mentioned welding 30, second, by the previously mentioned expansion or enlargement of the end portion of the handle inside the sleeve, and, third, by the fact that the material of the head H] serves as an agent to mechanically interlock the sleeve 2 with the handle 13. Thus, the fact that the expanded end portion of the handle i3 is embedded in the material of the head together with the fact that the head is embraced by the sleeve l2 in effect interlocks the sleeve and handle.

Although the now preferred embodiment of the present invention has been shown and described herein, it is to be understood that the invention is not to be limited thereto, for it is susceptible to changes in form and detail within the scope of the appended claims.

I claim:

1. A hammer of the character described comprising: a cylindrical head sleeve of rigid material having a peripheral opening; a handle having a hollow end portion projecting through said opening into said sleeve to extend transversely thereof; and a head casting occupying said sleeve and extending beyond at least one open end of the sleeve, the wall of the hollow end portion of said handle having at least one lateral opening through which the material of the head casting extends into said hollow portion of the handle, whereby the head casting rigidly interlocks the head sleeve and handle.

2. A hammer as set forth in claim 1 in which the cross-section of the material of the head casting inside said end portion of the handle is greater than the dimension of the opening whereby the head casting is interlocked with the handle.

3. A hammer of the character described, comprising: a cylindrical head sleeve of rigid material having a circular opening formed in the wall thereof; a tubular handle of circular cross-section having an end portion extending through said sleeve into the interior of the same; means bonding the end of said handle to the sleeve opposite said opening; and a head casting occupying said sleeve and extending beyond at least one open end of the sleeve, the wall of said end portion of the handle having a flared opening to form at least one passage through which the material of the casting extends for interlocking the head sleeve and casting, the flared opening providing a deformed end portion of the handle larger in cross-section than the opening of said sleeve.

4. A method of fabricating a hammer of the type described characterized by the use of hollow elongated stock material of tWo different crosssectional sizes, said method including the steps of: cutting a head sleeve from the larger stock; cutting an opening in the periphery of the head sleeve slightly larger than the cross-sectional dimension of said smaller stock; cutting a piece of said smaller stock to size to serve as a handle; cutting at least one longitudinal slot in an end portion of said handle; inserting said end portion into said head sleeve through said opening; welding the end of said handle to the wall of said head sleeve opposite said opening; widening said slot While said end portion is inside said head sleeve to expand said end portion; and casting a head to occupy the interior of said head sleeve and to extend into said handle through said slot to interlock the handle and sleeve.

5. As an article of manufacture, a hammer frame adapted for the casting of a head integral therewith, said frame comprising: a headsleeve of rigid material to embrace a central portion of said head, said sleeve having a centrally located peripheral opening therein; a hollow cylindrical handle having an end portion projecting into said sleeve through said opening and extending transversely of said sleeve, the end portion of said handle disposed within said sleeve being deformed to a cross-sectional dimension greater than the opening to hold said handle against separation from said sleeve; said end portion having an opening formed in the Wall thereof whereby the interior of said sleeve communicates with the interior of said handle to form a flow passage for the material of the head during the casting of the same.

6. As an article of manufacture, a hammer frame adapted for the casting of a head unitary therewith, said frame comprising: a head sleeve of rigid material to embrace a central portion of said head, said sleeve having a pair of diametrically opposed peripheral openings therein; a hollow cylindrical handle having an end portion extending radially into said sleeve through one of said openings with the terminal of said end portion fitting within the other of said opening; and means bonding the terminal of said end portion to the material of said sleeve contiguous to the defining edges of said other opening to join said handle to said sleeve, the end portion of said handle disposed within said sleeve being deformed to a cross sectional dimension greater than the openings to augment the jointure effected by said bonding means and to interlockingly hold said handle against separation from said sleeve and to form an anchoring means to be embedded within and interlockingly engaged with the material of the head as the same is cast.

7. A hammer of the type described, comprising: a head sleeve of rigid material, said sleeve having a pair of diametrically opposed peripheral openings therein; a hollow cylindrical handle having an end portion projecting into said sleeve through one of said openings and diametrically extending across said sleeve; means bonding the terminal portion of said handle to the material of said sleeve contiguous to the defining edges of said other opening, the end portion of said handle disposed within said sleeve having an opening therethrough, the defining edges of which are deformed to a cross-sectional dimension greater than the openings of said sleeve; and a head casting completely filling said sleeve and integrally extending through the opening of said handle to occupy at least the portion thereof disposed within said sleeve to rigidly interlock the head with the sleeve and handle.

8. A method of fabricating a hammer frame of the type described characterized by the use of hollow elongated stock material of two difierent cross-sectional sizes, said method including the steps of cutting a head sleeve from the larger stock; cutting an opening in the periphery of the head sleeve slightly larger than the cross-sectional dimension of said smaller stock; cutting a piece of said smaller stock to size to serve as a handle; cutting at least one longitudinal slot in an end portion of said handle; inserting said end portion into said head sleeve through said opening to dispose the slot for access through one open end thereof; welding the end of said handle to the wall of said head sleeve opposite said opening; and thereafter inserting a tool through said open end and swaging outwardly the defining edges of said slot to expand said end portion of ther handlei intozwasdivision larger in vcross-section than thecopem'ng: of said; head-sleeveito augment the!jointure.of -the-weldand to form an anchoring meansizaxlamted to be embedded :within and interlockingly engaged:withithematerial of a head subsequently cast-about said: head: sleeve and filling timer-same.

Name Date Number 'COburn Oct. 20, 1874 8 Number Name Date :1',035 ',655 iSwenson :Aug. 13, v 1912 -l,298;382 .-.Packer. Mar.--25, 1919 12,101,707 -Ewing :Dec. 7,1937 6 2179,0239 VHauf -Nov. 7,1939

OTHER "REFERENCES Safe Soft Metal Hammer, by Creider in AmericanMachinist, v01. 73,. No.16, .October 116,

10 1 pase.63.4. 

